Buried Static Dissipative Optical Construction
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Solution Overview
Problem
Optical films used in displays and other applications face issues with static charges leading to defects like unwanted light blockages, non-planar topography, and the 'wet-out' phenomenon, which affect light transmissivity and clarity, and existing static dissipative materials are ineffective in low humidity environments and may compromise light transmissivity.
Innovation Solution
The development of optical constructions with a static-dissipative layer buried between non-static-dissipative optical layers, which maintains static dissipation properties even at high surface resistivity and in low humidity, using conductive polymers and appropriate processing techniques like co-extrusion and lamination to ensure effective static charge dissipation without compromising light transmissivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductive compositions are coated onto the surface of optical films to impart anti-static properties, then static dissipation is improved, but light transmissivity and clarity deteriorate due to the highly colored nature of these compositions
Solution Approach 1:
The patent extracts the static-dissipative layer from the surface and buries it between non-static-dissipative optical layers. This allows the conductive polymer to maintain its static dissipation function while being hidden from view, eliminating its visual impact on light transmissivity and clarity.
Solution Approach 2:
The static-dissipative layer is nested between two non-static-dissipative optical layers, creating a sandwich structure. This nesting allows the conductive layer to be protected and concealed while maintaining its functional properties for static charge dissipation.
2Reliability
If ionic anti-static agents are used to provide static dissipation, then static charge dissipation is improved, but effectiveness deteriorates in low humidity environments (below 20% RH)
Solution Approach 1:
The patent changes the fundamental mechanism from ionic mobility (humidity-dependent) to electronic conduction through conductive polymers (humidity-independent). This parameter change allows the material to maintain consistent static dissipation performance across all humidity conditions.
Solution Approach 2:
The patent substitutes the mechanical/chemical mechanism of ionic migration with the electronic mechanism of conductive polymer charge transport. This substitution eliminates dependence on environmental humidity while maintaining static dissipation capability.
3Reliability
If conductive polymer compositions are applied to optical films, then static dissipation is improved, but the compositions may be susceptible to mechanical abrasion and optically disruptive effects
Solution Approach 1:
The patent applies non-static-dissipative optical layers over the conductive polymer layer before the product is put into service. These protective layers cushion and protect the fragile conductive polymer from mechanical abrasion and handling damage while maintaining optical clarity.
Solution Approach 2:
The conductive polymer layer is nested between protective optical layers, creating a protected sandwich structure. This nesting provides mechanical protection to the vulnerable conductive layer while allowing it to maintain its static dissipation function.
4Ease of manufacture
If static charges are present on optical films, then manufacturing processes become simpler, but defects such as particle adherence, non-planar topography, and wet-out phenomenon increase
Solution Approach 1:
The patent incorporates the static-dissipative layer during the manufacturing process itself, rather than adding it later. This preliminary action prevents static charge buildup during subsequent handling and assembly operations, thereby preventing defects like particle adherence and wet-out without complicating the manufacturing process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively negates static charge effects, prevents particle adherence, and maintains high light transmissivity and clarity, even in low humidity conditions, by ensuring the optical constructions remain static-dissipative with surface resistivity greater than 1×10^12 ohms/square and rapid static decay times, thus addressing the limitations of existing materials.
Implementation Method 1
conductive compositions have been developed since the introduction of conductive polymers such as polyethylenedioxythiophene (PEDT)
Implementation Method 2
These static charges can subsequently attract particles that may be near the surface of a film
Data Source
AI summary
A method of making an optical construction that is static-dissipative and includes a static-dissipative layer buried within optical material.